30/05/2024 08:30:01

Door Assembly - Front - LH (Remove and Replace)

Correction Code 10106002

  • 2023-11-21: Added rework instructions to enable fitting of early type pressure sensor to new type door.
  • 2023-08-22: Revised procedure using the latest vehicle validation.

Removal

  1. Open the LH front door and lower the window.
  2. Remove the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace).
  3. Latch the LH front door to allow the window to fully raise.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not close the door with the window in this position, as upper bright trim will be damaged.
  4. Apply masking tape to the LH front door handle grip to prevent damage to the chrome surface of the grip.
  5. Remove the LH front door panel. See Panel - Door Trim - Front - LH (Remove and Install).
  6. Remove the LH front window outer belt seal.
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    Note
    Lift and roll outward slowly and evenly starting from the rear edge. Be careful not to bend or damage components.
  7. Remove the LH front inner belt seal from the upper door assembly.
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    Note
    Take care not to bend the inner belt seal during removal.
  8. Connect the window switch tool to the vehicle.
  9. Fully raise the LH front window.
  10. Remove butyl patch and door tape.
  11. Disconnect the door harness connector to LH front door speaker.
  12. Remove the screws (x4) that attach the LH front door speaker to the spacer ring.
  13. Remove the screws (x4) that attach the speaker spacer ring to the door shell.
  14. Loosen the nut that attaches the LH front window glass to the window regulator.
  15. Roll window up or down so that the regulator clip is visible, depress the clip and lift on glass to remove from the regulator clip and door body.
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    Note
    Place door glass in a safe area while working on the vehicle to prevent damage.
  16. Remove the upper door clips (x4) from the door assembly.
  17. Disconnect the window switch tool from the LH front door harness.
  18. Disconnect 12V power. See Disconnect 12V Power.
  19. Disconnect the exterior door mirror connectors (x2).
  20. Remove the clip on the door flap seal to gain access to the exterior mirror assembly bolts.
  21. Remove the bolts (x3) of the exterior mirror assembly.
  22. Remove the foam seal from the exterior mirror assembly.
  23. Remove the exterior mirror assembly from the vehicle.
  24. Remove the pressure sensor from the door:
    • Vehicles built before February 11, 2019: Remove the screws (x2) that attach the pressure sensor to the door (torque 5 Nm), and then disconnect the sensor harness.
    • Vehicles built after February 11, 2019: Depress the locking tab on the pressure sensor, and then pull the connector away from the sensor. Rotate the pressure sensor clockwise 90 degrees to remove the pressure sensor from the door.
  25. Disconnect the door harness connector to the door handle controller.
  26. Disconnect the door harness connectors (x3) to the door control unit.
  27. Remove the LH front door closeout panel.
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    Note
    6x bolts, T25, 4 Nm. 1x clip to door wiring harness
  28. Remove the plugs (x2) that covers the LH front window regulator lower nuts.
  29. Remove the lower nuts (x2) from the LH front window regulator
  30. Remove the upper nuts (x2) from the LH front window regulator.
  31. Remove the screws (x3) that attach the regulator motor to the door.
  32. Disconnect the harness connector and remove the LH front window regulator from the door assembly.
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    Note
    Pivot the LH front window regulator counterclockwise and release it through the closeout opening in the door assembly.
  33. Disconnect the 3.0 door handle harness from the LH front door handle assembly.
  34. Remove the nuts (x4) that attach the LH front door handle to the door.
  35. Remove the LH front door handle through the access opening.
  36. Remove the bolts (x2) that attach the latch to the door assembly.
  37. Remove the door latch from the door assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector. Carefully release the latch assembly from the door outer panel, and then disconnect the latch harness connector.
  38. Release the clips that attach the LH front door harness to the door assembly.
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    Note
    12x clips, 1x rubber grommet
  39. Remove the LH front door seal from the door assembly.
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    Note
    22x clips.
  40. Remove the LH front door harness from the door assembly.
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    Note
    1x grommet.
  41. Remove the bolts (x4) that attach the LH front door assembly to the hinges, remove the door from the vehicle and put it on a padded surface.
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    Note
    Assistance is recommended.

Installation

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CAUTION
If using this procedure to install an unpainted part, make sure to apply seam sealer to all seams prior to installing and painting the part. Refer to the Collision Repair manual for more information.
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Note
When replacing an old type door (vehicles built before February 11, 2019) with a new one, the door needs to be reworked to enable fitting of the old pressure sensor to the new door. For details, see TN-19-10-001 - Rework Front Door Panel For Earlier Pressure Sensor Design .
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Note
If the door needs to be reworked, add correction code 10106007 (LH door) or 10106107 (RH door) as a separate activity to the Service Visit.
  1. Install the bolts (x4) that attach the LH front door assembly to the hinges on the vehicle (torque 31 Nm).
  2. Insert the LH front door harness into the door assembly and attach the grommet to the door assembly.
  3. Install the LH front door seal onto the door assembly.
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    Note
    22x clips.
  4. Attach the LH front door harness to the door assembly.
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    Note
    12x clips, 1x rubber grommet
  5. Install the bolts (x2) that attach the latch to the door assembly (torque 10 Nm).
  6. Connect the door harness connector to the latch assembly.
  7. Install the nuts (x4) that attach the door handle assembly to the LH front door, and then hand tighten the nuts.
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    Note
    Leave hardware loose enough so that door handle assembly can be moved for alignment
  8. Align the door handle and torque the nuts (x4) to 9 Nm.
  9. Connect the 3.0 door handle harness to the door handle assembly.
  10. Adjust the LH front door handle for flushness to the door.
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    Note
    1x adjustment screw, T40. Flush measurement of door handle should be adjusted to similar flush measurements of other handles on the vehicle.
  11. Install the LH front window regulator into the door assembly.
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    Note
    1x connector. Position LH front window regulator into the closeout opening in the door assembly and pivot it clockwise to put it into place.
  12. Install the nuts (x4) that attach the LH front window regulator to the door assembly (torque 10 Nm).
  13. Install the access plugs (x2) onto the door assembly.
  14. Install the screws (x3) that attach the regulator motor to the door assembly (torque 2.4 Nm).
  15. Install the screws (x4) that attach the spacer ring to the door shell (torque 1.8 Nm).
  16. Install the screws (x4) that attach the LH front door speaker to the spacer ring (torque 1.8 Nm).
  17. Connect the door harness connector to the LH front door speaker.
  18. Install the upper door clips (x4) onto the door assembly.
  19. Inspect the mirror area of the door assembly.
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    Note
    2x nylon shims. Make sure that both nylon shims are present. Replace if damaged or missing.
  20. Install the bolts (x3) that attach the exterior mirror to the door assembly (torque 18 Nm).
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    Note
    Make sure that the wiring harness connector is inboard of the door. Failure to install the fasteners using the following sequence can result in NVH issues
  21. Install the exterior mirror foam.
  22. Install the door seal flap retaining clip.
  23. Connect the mirror connectors (x2).
  24. Install the front door pressure sensor:
    • Vehicles built before February 11, 2019: Install the screws (x2) that attach the pressure sensor to the door (torque 5 Nm), and then reconnect the harness to the pressure sensor.
    • Vehicles built after February 11, 2019: Rotate the pressure sensor counter clockwise 90 degrees to secure the pressure sensor to the door, and then reconnect the harness to the pressure sensor.
  25. Install the screws (x6) that attach the LH front door closeout panel to the door (torque 4 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the inner door handle manual release cable is routed properly.
  26. Connect the door harness connector to the door handle controller.
  27. Connect the door harness connectors (x3) to the door control unit.
  28. Connect 12V power. See Disconnect 12V Power.
  29. Connect the window switch tool to the vehicle.
  30. Install the door glass and lower the window.
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    Note
    Make sure to slide the glass into the track mounted on the front quarter glass.
  31. Install the LH front inner belt seal.
  32. Close the LH front door.
  33. Install the outer belt seal to the LH front door.
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    Note
    Use P-80 Emulsion lubricant to lube belt molding for easy installation and gap adjustment
  34. Adjust the glass to within specifications.
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    Note
    1x nut, 10mm, 7.5 Nm. Measure at the end of the door seal radius #1, right above the Tesla logo #3, and half way between 1 and 3.
  35. Open the LH front door.
  36. Torque the nut that attaches the regulator to the moving glass (torque 7.5 Nm).
  37. Verify correct operation of the LH front window.
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    Note
    Cycle the LH front window, and listen and look for contact between the regulator and the wiring harness during operation. Make sure that the door handle harness and connectors are clear of the path of the regulator and moving glass.
  38. Install stickers over the holes in the inner door.
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    Note
    5x stickers. Replace if damaged or missing.
  39. Disconnect the window switch tool from the LH front door harness.
  40. Install the LH front A-pillar margin seal onto the door assembly.
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    Note
    3x clips. Align the margin seal onto the LH front edge of the door assembly. Peel off adhesive backing and attach the seal onto the door assembly.
  41. Install the LH front door panel clips.
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    Note
    Install new clips (x9). Attach felt tape around the clips
  42. Gently spread the upper door clips (x5) with a screwdriver to ensure adequate holding force to the door panel.
  43. Install the LH front door panel. See Panel - Door Trim - Front - LH (Remove and Install).
  44. Install the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace).